How to make a bioreactor with your own hands

Searching for a less carbon-footprinting and environmentally friendly way to heat your house? The answer you’ve been looking for may lie in building your own bioreactor. A bioreactor is an apparatus that naturally ferments organic materials to generate heat. We’ll walk you through the steps of building your very own bioreactor at home in this article.

By lowering your dependency on fossil fuels, using a bioreactor not only helps you save money on heating but also helps the environment. You can create heat with as little environmental impact as possible by using organic materials like food waste, yard clippings, or other biomass.

As a fun do-it-yourself project for you and your family, building a bioreactor is actually easier than you might think. You’ll learn more about how organic materials can be used to produce energy in a renewable and environmentally friendly manner in addition to developing a sustainable heat source for your house.

What biogas is and how it is formed

After processing biomass, biogas is produced.

Fuels that are good for the environment are called biogas. In many ways, the properties of biogas are identical to those of natural gas produced commercially. The following is a presentation of biogas production technology:

• in a special container called a bioreactor, there is a process of biomass processing with the participation of anaerobic bacteria under conditions of airless fermentation for a certain period, the duration of which depends on the volume of loaded raw materials;
• As a result, a mixture of gases is released, consisting of 60 % methane, 35 % carbon dioxide, 5 % other gaseous substances, including hydrogen sulphide in small quantities;
• The gas produced is continuously discharged from the bioreactor and, after purification, it is sent for its intended use;
• The processed waste, which has become high quality fertilizer, is periodically removed from the bioreactor and transported to the fields.

An outline of the method used to produce biofuel

To generate biogas continuously at home, one needs access to or ownership of livestock and agricultural facilities. Producing biogas is only financially feasible in the presence of a free source of manure and other organic animal waste.

Gas heating remains the most dependable type of heating. The following resources can be used to learn more about autonomous gasification: https://aqua-rmnt.com/gazosnabzhenie/avtonomnoe-gazosnabzhenie-chastnogo-doma.html

Are you trying to cut back on your heating expenses and lessen your impact on the environment? A sustainable option might be to construct your own bioreactor. You can produce biogas—your own renewable energy—by using organic materials like food waste and yard clippings. You can build a bioreactor that converts waste into energy and helps heat your house while lessening your environmental impact with a few easy steps and some common materials.

Types of bioreactors

The way that feedstock is loaded, how the produced gas is collected, where the reactor is located in relation to the ground, and the building materials used all vary amongst biogas production facilities. Steel, concrete, and brick are the best materials to use when building a bioreactor.

Bioreactors are classified according to the type of loading; those that load a specific amount of feedstock, process it for a cycle, and then unload it entirely are distinguished from those that don’t. Although the units’ gas production is unstable, any kind of feedstock can be fed into them. Usually, they are stacked vertically and occupy minimal room.

The second kind of system takes in a load of organic waste every day and releases the same amount of finished fermented fertilizer out of it. The reactor is always filled with a working mixture. Farmers love the so-called continuous loading system because it consistently generates more biogas. These reactors are generally horizontally oriented and useful when there is available space at the location.

The reactor’s design features are determined by the type of biogas collection that is chosen.

• cylinder systems consist of a rubber or plastic heat-resistant cylinder that combines a reactor and a gas holder. The advantages of this type of reactor are simplicity of construction, feedstock loading and unloading, ease of cleaning and transportation, low cost. The disadvantages are a short service life, 2-5 years, the possibility of damage due to external influences. The cylinder reactors also include channel-type plants, which are widely used in Europe for processing liquid waste and wastewater. This rubber top is effective at high ambient temperature and there is no risk of damage to the cylinder. The fixed dome design has a fully enclosed reactor and a compensating sludge discharge tank. Gas accumulates in the dome, when loading the next portion of feedstock, the processed mass is pushed into the compensation tank.
• Floating dome biosystems consist of a monolithic bioreactor located underground and a movable gas holder that floats in a special water pocket or directly in the feedstock and rises under the action of gas pressure. The advantage of a floating dome is the ease of operation and the ability to determine the gas pressure by the height of the dome elevation. This is an excellent solution for a large farm.
• When choosing an underground or above-surface installation, one should take into account the slope of the relief, which facilitates the loading and unloading of raw materials, the reinforced thermal insulation of underground structures, which protects biomass from daily temperature fluctuations and makes the fermentation process more stable.

Extra devices for heating and mixing raw materials can be incorporated into the design.

Is it cost-effective to make a digester and use biogas?

When building a biogas plant, the following goals are in order:

• production of cheap energy;
• production of easily digestible fertilizers;
• saving on connection to expensive sewage system;
• recycling of farm waste
• possible profit from gas sales;
• reduction of odor intensity and improvement of ecological situation on the territory.

A graph showing the profitability of producing and using biogas

The astute landlord should take into account the following factors when evaluating the advantages of constructing a bioreactor:

• the costs of biogas installation are long-term investments;
• Homemade biogas equipment and reactor installation without hiring outside specialists will cost much cheaper, but also its efficiency is lower than that of expensive factory equipment;
• To maintain a stable gas pressure, the farmer must have access to sufficient quantities of animal waste for a long period of time. In case of high electricity and natural gas prices or no gasification is possible, the use of the plant becomes not only profitable but also necessary;
• For large farms with their own raw material base, a favorable solution will be the inclusion of a bioreactor in the system of greenhouses and cattle farms;
• For small farms, the efficiency can be increased by installing several small reactors and loading the feedstock at different intervals. This will avoid interruptions in gas supply in case of lack of feedstock.

How to build a bioreactor on your own

After deciding to build, you must now design the plant and determine how much material, equipment, and tools will be needed.

Crucial! The fundamental prerequisite for bioreactor material is resistance to aggressive acidic and alkaline media.

If a metal tank is available, it should be used as long as it is coated to prevent corrosion. Consider the strength and presence of welds when selecting a metal tank.

A polymer container is a practical and long-lasting choice. This substance doesn’t rust or decay. The load will be easily supported by a reinforced barrel or one with thick, rigid walls.

Building the tank out of concrete, stone, or brick is the least expensive option. The walls are strengthened and coated with a multilayer waterproofing and gas-tight coating on the inside and outside to increase their strength. Additives that offer the required qualities ought to be present in the plaster. The ideal shape, either oval or cylindrical, will enable it to sustain all pressure loads.

A hole is provided at the bottom of the tank to allow waste material to be removed. This gap needs to be sealed tightly since the system can only function properly in hermetic environments.

Calculation of necessary tools and materials

To lay out the brick tank and construct the entire system, the following equipment and supplies will be required:

• A cement mortar mixing tank or concrete mixer;
• a drill with a mixer attachment;
• crushed stone and sand for a drainage cushion;
• shovel, tape measure, trowel, trowel;
• brick, cement, water, fine sand, rebar, plasticizer and other necessary additives;
• welding machine and fasteners for mounting metal pipes and components;
• water filter and a container with metal shavings for gas cleaning;
• tire cylinders or standard propane cylinders for gas storage.

A private farmstead or farmhouse’s daily production of organic waste determines the size of the concrete tank. If the bioreactor is filled to two thirds of its total volume, it can operate at full capacity.

Let"s determine the volume of the reactor for a small private farm: if there are 5 cows, 10 pigs and 40 chickens, then for a day of their vital activity is formed droppings 5 x 55 kg + 10 x 4.5 kg + 40 x 0.17 kg = 275 kg + 45 kg + 6.8 kg = 326.8 kg. To bring chicken manure to the required moisture content of 85% you need to add 5 liters of water. Total weight = 331.8 kg. To recycle in 20 days you need: 331.8 kg x 20 = 6636 kg – about 7 cubic meters of substrate alone. This is two thirds of the required volume. To get the result, you need 7×1.5= 10.5 cubic meters. The obtained value is the required volume of the bioreactor.

Keep in mind that tiny tanks cannot produce a significant volume of biogas. The amount of organic waste processed in the reactor directly affects the yield. Therefore, processing a ton of organic waste is required to produce 100 cubic meters of biogas.

Preparation of the place for the device of the bioreactor

Selecting a location for the construction of a reinforced concrete tank—which will function as a bioreactor—is essential to obtaining free biofuel on the plot.

The best spot is selected away from areas used for animal housing and living quarters. Storage for feedstock may be close by. The level of groundwater and the ease of loading and unloading biomass are important considerations. It is a preferred location for raw material delivery.

Building the reactor vessel below ground level is a cost-effective option. Additionally, the relief’s slope is quite practical. This will make loading organic substrate easier and lower the cost of thermal insulation.

The preparation of the pit’s walls and bottom for the tank directly affects the reactor’s longevity and construction quality. Concrete, plastic, and polymer rings are used to strengthen walls and seal them. It is a comprehensive and significant insulation. Use improvised materials such as straw, clay, dry manure, and slag as a low-cost insulator.

Assembly and installation of the installation

Installing a straightforward, dependable design with no frills is the best way to save money. Later, as the system is used and opportunities to add more components for automation, control, and heating present themselves, those elements can be added.

An example of a bioreactor diagram

Detailed guidelines for putting together and setting up the bioreactor will enable you to install the plant on your own.

1. Dig an excavation, pour a leveling layer of sand at the bottom, cover the whole excavation with PVC film, then pour a heat-insulating layer of expanded clay, straw, level the horizon. Assemble pipes for substrate loading and unloading. The diameter of pipes for raw materials should be at least 300 mm, otherwise they will get clogged.
2. Lay a brick tank or install a ready-made one. Insulate the side walls of the reactor by covering them with clay and straw in several layers or using modern insulators, e.g. polystyrene foam, expanded polyurethane foam.
3. Make a gas drainage system consisting of vertical pipes with numerous holes in the enclosure. This system will replace the agitators.
4. Cover the outer layer of the loaded biosolids with a special film to create a slight overpressure and accumulation of biogas under the dome. Install the dome, which should be hermetically sealed and the gas outlet pipe on top, filters for cleaning, airtight manhole, odor trap. Gas is accumulated and stored in special bags-gas holders.

Start up the bioreactor

1. For effective operation of the bioreactor it is necessary to load it with raw materials on 2/3 of the volume, the necessary temperature for the work of bacteria, so the hopper for biomass feeding should be located on the sunny side, so that it warms up.
2. It is cheaper and easier to load new and remove the spent organic substrate using the principle of overflow, i.e., the fermentation process is started at the temperature at which the fermentation is started.е. The rising level of organics inside the reactor when a new batch is introduced will discharge the substrate through the discharge pipe in a volume equal to the volume of the introduced material.
3. Load a batch of bacteria. Heat if necessary.

Proper venting of gas from the bioreactor

The upper portion of the lid has a specific hole that allows the gas generated during the fermentation of organic materials to be released while the tank is securely sealed. To ensure that the biogas does not mix with the air, it needs to be released via an odor-absorbing water trap.

The lid of the bioreactor, which functions as a release valve in the event of an excess of gas, can be used to regulate the pressure of the gas mixture inside. A counterweight can be made out of any regular weight. The generated gas will travel through a discharge pipe and be cleaned in water en route to the gas holder if the pressure is normal.

The resultant gas is released via a unique aperture in the lid structure.

Operating and safety instructions

The biogas plant will operate properly if batches of fertilizer are continuously loaded and unloaded and the fermentation conditions are controlled.

Batches of organics fermenting bacteria for the production of biogas are sold by specialized companies.

Bacteria can be classified as thermophilic, psychrophilic, or mesophilic. It will take 12 days for the organic matter to completely ferment with thermophilic bacteria. Because mesophilic bacteria are slower, it will take them 20 days to process the raw material.

In order to prevent a crust from forming on the surface of the biomass in the reactor and prevent the biogas from escaping freely, the biomass must be stirred at least twice a day. The reactor should be heated in the winter to maintain the ideal temperature for the maximum amount of product output.

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No antiseptics, detergents, or other chemicals that damage bacteria or slow down the production of biogas can be present in the organic mixture that is loaded into the reactor.

Crucial! Biogas is explosive and combustible.

The bioreactor must operate according to the same regulations as any other gas installation. There won’t be any issues if the apparatus is sealed and the biogas is released into a gas holder on schedule.

It is advised to install temperature and pressure sensors in the reactor because there is a risk of explosion if the gas pressure is higher than usual or if it leaks when the tightness is broken. The health of humans is also at risk when inhaling biogas.

How to ensure biomass activity

Heat treatment of the biomass can quicken its fermentation process. Southern regions typically do not experience this issue. The temperature of the surrounding air is adequate to trigger fermentation processes naturally. It is impossible to run a biogas plant without heating during the winter in areas with severe weather. After all, temperatures higher than 38 degrees Celsius initiate the fermentation process.

There are various ways to arrange the heating of the biomass tank:

• Connect the coil located under the reactor to the heating system;
• install electric heating elements at the base of the tank;
• Provide direct heating of the tank by using electric heaters.

Within the feedstock itself, the bacteria that influence the production of methane are dormant. There is a temperature at which they become more active. The process will proceed normally if an automated heating system is installed. When the following cold batch enters the bioreactor, the automation will activate the heating apparatus; it will then switch off when the biomass reaches the desired temperature.

These temperature control systems are available for purchase in gas equipment specialty stores, where they are installed in hot water boilers.

The entire cycle is depicted in the diagram, beginning with the loading of raw materials—both liquid and solid—and concluding with the biogas discharge to consumers.

It’s crucial to remember that you can stir the biomass in the reactor to start producing biogas at home. To this end, a device that resembles a home mixer is constructed. A shaft that is led through a hole in the tank’s walls or lid can power the apparatus.

Anyone who wants to produce renewable energy and lessen their impact on the environment may find building their own bioreactor to be an exciting and rewarding project. You can use readily available materials to build a basic bioreactor that is still highly effective by following the instructions provided in this guide. Building your own bioreactor can be an environmentally friendly way to meet your energy needs, regardless of whether you want to use the biogas you produce for heating, cooking, or lighting.

Building your own bioreactor offers the chance to recycle organic waste products and transform them into useful energy. Food scraps, yard waste, or animal manure can all be used as feedstock to create biogas and lessen the quantity of waste that is dumped in landfills. This not only helps you reduce your carbon footprint but also gives you the opportunity to manage waste more proactively.

Furthermore, DIY bioreactors can be built and maintained for comparatively little money, making them affordable for a wide range of financial situations. You may build a bioreactor that satisfies your energy requirements and stays within your price range with just a few simple tools and supplies. A DIY bioreactor can be an affordable option for anyone looking to cut utility costs or become energy independent, be they a small-scale farmer or homeowner.

And lastly, you can learn more about this renewable energy technology by constructing your own bioreactor. You can increase the efficiency of your bioreactor and the amount of biogas it produces by experimenting with different feedstocks, temperatures, and mixing ratios. This practical experience not only gives you valuable knowledge that you can impart to others in your community, but it also helps you become more self-sufficient.

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